Apparatus for assembling insole strips

ABSTRACT

A machine for assembling diverse strip materials into a composite edge-laminated sheet from which insoles for shoes can be cut is disclosed. Stacks of insole strip materials are arranged on aligned, side by side loading platforms in a feeder portion of the machine. Adjacent edges of contiguous strips may be beveled to permit edge bonding by the machine into a single, composite, flat sheet. A vacuum device in the feeder portion picks up the top strips from each stack and delivers them to corresponding parallel endless belts. The strip from the centrally located loading platform and the strips from the two adjacent platforms are delivered to a first adhesive station where a hot melt adhesive is applied to the edges of the central strip or the corresponding inside edges of the outer strips. After passing the adhesive section, the strips are delivered to an assembly station where the two adjacent strips are moved laterally into alignment with the edges of the central strip. The three strips are then bonded together by being passed through suitable nip and pressure rolls. The resultant intermediate sheet is passed through a second adhesive section, where adhesive is applied to the outer edges, or the corresponding inside edges of the remaining strips, and then passes to a second assembly section. The remaining outer strips are then aligned with the edges of the intermediate sheet for joining by passing through a second set of nip and pressure rolls. The finished composite sheet is then delivered to a stacking station and subsequently may be cut into individual insoles of the desired size and composition.

United States Patent 51 3,661,681 Edelberg et al. 1 May 9, 1972 54] APPARATUS FOR ASSEMBLING 57 ABSTRACT INSOLE STRIPS A machine for assembling diverse strip materials into a com- [72] Inventors; Alan m Cincinnati, Ohio; Roy posite edge-laminated sheet from which insoles for shoes can S fddt Burlington Mass. be cut is disclosed. Stacks of insole strip materials are arranged on aligned, side by side loading platforms in a feeder [73} Asslgnee: T "3 States shoe Corporation portion of the machine. Adjacent edges of contiguous strips cmnan Ohlo may be beveled to permit edge bonding by the machine into a 32 Filed; Sept 1 9 9 single, composite, flat sheet. A vacuum device in the feeder portion picks up the top strips from each stack and delivers [2l] Appl. No.: 859,143 them to corresponding parallel endless belts. The strip from the centrally located loading platform and the strips from the 521 U.S. c1 ..156/546, 156/304, 156/557, two adjacent Platforms are delivered to a first adhesive Station 156/559 where a hot melt adhesive is applied to the edges of the central [51] Int. Cl. ..B32b 31/12, B32b3l/2O strip or the corresponding inside edges of the outer strips. [58] Field of Search 1 56/209, 304, 352, 362, 363, After passing the adhesive section, the strips are delivered to 156/366, 367, 538, 539, 543, 544, 546, 547, 556, an assembly station where the two adjacent strips are moved 557-561 laterally into alignment with the edges of the central strip. The three strips are then bonded together by being passed through References Ciled suitable nip and pressure rolls. The resultant intermediate sheet is passed through a second adhesive section, where ad- UNITED STATES PATENTS hesive is applied to the outer edges, or the corresponding in- 2,31 1,766 2/1943 Lumbard ..l56/304 X Side ges Of the remaining strips, and then passes to a second 2,548,527 4/1951 G ff ,156/556 X assembly section. The remaining outer strips are then aligned 2,708,649 5/1955 Cunningham.. ...,l56/559 X with the edges of the intermediate sheet for joining by passing 2,723,936 ll/l955 Ryan ....l56/209 through a second set of nip and pressure rolls. The finished 3,084,090 4/1963 Rambo et al... ....156/299 composite sheet is then delivered to a stacking station and 3,185,130 5/l965 Pratt ....156/546 X subsequently may be cut into individual insoles of the desired 3,25 L722 5/l966 Holman ....l56/368 X size and composition. 3,306,805 2/1967 Klein et a] ..156/470 41 Claims, 32 Drawing Figures Primary Examiner-Benjamin A. Borchelt Assistant Examiner-J. M. Hanley Attorney-Jones & Lockwood I i I i l L l 4 I I)-' I I w s;

I I I I 1 I I i I i K I Jo I? I l l I i 1 V. L; Z; l I I I I I I i l I i I 5 I T "1 l x l I I .QJI "n i L/ I 6 I r i I I I Patented May 9, 1972 21 Sheets-Sheet 2 f ib 60 Patented May 9, 1972 21 Sheets-Sheet 5 Patented May 9, 1972 3,661,681

21 Sheets-Sheet 4 FIG. 40

Patented May 9, 1972 3,661,681

21 Sheets-Sheet 5 ALA/V K. EDELBERG R0) 7. SWA/VFELDT Patented May 9, 1972 3,661,681

21 Sheets-Sheet 6 FIG. 53

Patented May 9, 1972 21 Sheets-Sheet 7 Patented May 9, 1972 21 Sheets-Sheet 8 Patented May 9, 1972 21 SheetsSheet 9 Patented May 9, 1972 3,661,681

21 Sheets-Sheet 10 12 W r" l &J

( l 0: m 9' k Patented May 9, 1972 3,661,681

21 Sheets-Sheet 12 Patented May 9, 1972 21 Sheets-Sheet 14 n mun Patented May 9,1972 3,661,681

21 Sheets-Sheet 16 Patented May 9, 1972 

1. A machine for edge laminating a plurality of strips to form a composite sheet comprising a feeder section, a first adhesive section, a first assembly station, and a first roller sectIon, means for conveying a first one of said strips from said feeder section through said adhesive section to said first assembly station, means for conveying a second strip to said first assembly station, means in said first assembly station for aligning the leading edges of said first and second strips in a plane perpendicular to their common direction of travel and thereafter aligning corresponding edges of said strips in a common vertical plane, said strips being vertically spaced, and means for conveying said first and second aligned strips in synchronism through said first roller section to move said strips toward each other, thereby joining said strips and forming said sheet.
 2. The machine of claim 1, wherein said feeder section comprises means for receiving stacks of said strips and means for removing one strip at a time from each stack for deposit on corresponding conveying means.
 3. The machine of claim 1, wherein said first adhesive section includes means for applying adhesive to at least one edge of said first strip, whereby said first strip can be joined to said second strip along said edge.
 4. The machine of claim 1, wherein said first roller station includes a nip roll and a pressure roll for bonding corresponding edges of said strips to form said edge laminated composite sheet.
 5. The machine of claim 1, wherein said first adhesive section includes means for applying adhesive to at least one edge of said first strip as said first strip is being conveyed to said first assembly station.
 6. The machine of claim 5, wherein said second strip is conveyed directly to said first assembly station, said first assembly station including means for aligning said one adhesive-coated edge of said first strip with a corresponding edge of said second strip.
 7. A machine for edge laminating a plurality of strips to form a composite sheet comprising a feeder section, a first adhesive section, a first assembly station, and a first roller section, means for conveying a first one of said strips from said feeder section through said adhesive section to said first assembly station, means for conveying a second strip to said first assembly station, means in said first assembly station for longitudinally aligning said first and second strips, means responsive to the longitudinal alignment of said first and second strips for vertically aligning corresponding edges of said strips, and means for conveying said first and second aligned strips in synchronism through said first roller section to join said strips and form said sheet.
 8. The machine of claim 7, further including means responsive to the vertical alignment of said strips for energizing said means for conveying said strips through said first roller station.
 9. The machine of claim 8, said first roller station includes a nip roll and a pressure roll for bonding said corresponding edges of said first and second strips, thereby forming said composite sheet.
 10. In an assembly machine for edge bonding strips of material to form a composite sheet, a first adhesive station, means for conveying a first strip through said adhesive station while coating one edge of said strip with adhesive, means for longitudinally aligning and thereafter vertically aligning said adhesive-coated edge of said first strip with a corresponding edge of a second strip, and means responsive to said longitudinal and vertical alignment for pressing said edges together to join said strips.
 11. The assembly machine of claim 10, further including control circuit means for said machine, said control circuit having a drive motor control circuit for regulating said means for conveying, sensing means responsive to the locations of said strips for operating said means for aligning, and sensing means for advancing said strips to said means for pressing, whereby strips are sequentially fed through said adhesive station, aligned, and pressed to form composite sheets automatically.
 12. The assembly machine of claim 10, further incLuding a second adhesive station, means for conveying the sheet formed from said first and second strips through said second adhesive station while coating one edge of said sheet with adhesive, means for longitudinally and vertically aligning the adhesive-coated edge of said sheet with a corresponding edge of a third strip, and means for pressing said last-named corresponding edges together to join said sheet and said third strip.
 13. The assembly machine of claim 12, further including control circuit means for synchronizing the operation of said machine, whereby sets of first, second and third strips may be fed to said machine in timed sequence automatically to form a plurality of said composite sheets.
 14. The assembly machine of claim 13, further including feeder means for supplying said strips, said feeder means including first, second and third platforms for receiving stacks of said first, second and third strips, respectively, and means for drawing and feeding to a corresponding conveyor the topmost strip from each stack.
 15. The assembly machine of claim 14, wherein said means for drawing and feeding the topmost strip from each stack comprises at least one suction head assembly movable in a reciprocating path to pick up and deliver said strip, said suction head assembly including a suction head, guide block means reciprocable on a horizontally extending arm and supporting said suction head, said suction head being vertically movable with respect to said guide block, and cam means adjacent said arm for causing said suction head to move vertically with respect to said guide block as said suction head is reciprocated horizontally along said arm.
 16. The assembly machine of claim 15, wherein said first, second and third platforms are vertically movable to maintain the topmost strip of each stack accessible to said suction head assemblies, said control circuit means further including sensing means responsive to an empty platform to disable said suction head assembly.
 17. The assembly machine of claim 15, said control circuit means further including means responsive to a malfunction in said machine to disable said suction head assembly and to shut down the remainder of said assembly machine a predetermined time thereafter.
 18. The assembly machine of claim 13, wherein said means for vertically aligning said first and second strips comprises means for moving one of said first and second strips laterally with respect to the other of said first and second strips, whereby one of said corresponding edges is disposed above the other.
 19. The assembly machine of claim 18, wherein said means for vertically aligning the said corresponding edges of said sheet and said third strip comprises means for moving said strip laterally with respect to said sheet to dispose one of said corresponding edges vertically above the other.
 20. The assembly machine of claim 19, further including feeder means for supplying said strips, said feeder means including first, second and third platforms for receiving stacks of said first, second and third strips, respectively, and means for simultaneously drawing and feeding to a corresponding conveyor the topmost strip from each stack whereby a set of strips is fed to said assembly machine.
 21. In an automatic assembly machine for edge bonding diverse strips of material to form composite sheets, a first applicator station for applying adhesive to two edges of a first strip; a first assembly station; means for conveying said first strip to said first assembly station and into longitudinal alignment with second and third strips whereby the leading edges of said strips are in a plane perpendicular to their common direction of travel; means at said assembly station for vertically aligning corresponding edges of said second and third strips with said adhesive-coated edges of said first strip, said corresponding edges of said strips being in common vertical planes and vertically spaced; a roller station; means for advaNcing said first, second and third aligned strips in synchronism into said roller station to press said vertically spaced corresponding edges together, thereby joining said strips and forming a sheet; a delivery station; and means for feeding said sheet to said delivery station.
 22. The automatic assembly machine of claim 21, wherein said first applicator station comprises roller applicator means for applying a liquid adhesive to the edge surfaces of said first strip, the spacing of said roller applicator means being adjustable to receive strips of various widths.
 23. The automatic assembly machine of claim 21, wherein said first assembly station includes a first platform for receiving said first strip and support means for receiving said second and third strips, second and third platforms adjacent said first platform, and means responsive to longitudinal alignment of said strips for moving said second and third strips laterally onto said second and third platforms and into vertical edge alignment with said first strip.
 24. The automatic assembly machine of claim 23, wherein the level of said second and third platforms is below that of said first platform, whereby the edges of said second and third strips are spaced below the corresponding edges of said first strip when vertically aligned.
 25. The automatic assembly machine of claim 24, wherein said means for laterally moving said second and third strips comprises motor driven lug means, and control circuit means for operating said lug means only when said strips are longitudinally aligned.
 26. The automatic assembly machine of claim 21, wherein said means for advancing said first, second and third strips into said roller station comprises a plurality of suction heads spaced above said strips and adapted to pick up said strips, and means for moving said suction heads toward said roller station thereby to carry said strips to said roller station.
 27. The automatic assembly machine of claim 26, wherein said means for conveying said first strip into longitudinal alignment includes stop gate means for limiting the travel of said first strip, and wherein said means for advancing said first, second and third strips into said roller station further comprises means for sensing said vertical alignment and thereafter retracting said stop gate and activating said means for moving said suction heads.
 28. The automatic assembly machine of claim 21, further including a main drive train, means for selectively connecting said drive train to said applicator station, said first assembly station, said conveying means, said alignment means, and said roller station; and a control circuit for operating said means for selectively connecting said drive train, whereby sets of first, second and third strips are edge bonded to form said sheets.
 29. The automatic assembly machine of claim 28, said control circuit including first sensor means to detect the longitudinal alignment of said first, second and third strips, and timer means for disabling said drive train if said strips are not longitudinally aligned within a predetermined time period.
 30. The automatic assembly machine of claim 29, said control circuit further including means responsive to said first sensor means for operating said drive train to vertically align corresponding edges of said first, second and third strips, and second sensor means for detecting said vertical alignment.
 31. The automatic assembly machine of claim 30, said control circuit further including means responsive to said second sensor means to activate said means for advancing said first, second and third strips into said roller station.
 32. The automatic assembly machine of claim 31, said control circuit further including manual override means whereby said machine can be manually controlled.
 33. The automatic assembly machine of claim 21, further including feeder means for supplying said strips to said applicator station and said first assembly station, said feeder means being adapTed to supply to said machine sets of three strips at spaced time intervals for assembly into sheets.
 34. The automatic assembly machine of claim 33, further including a first conveyor for carrying said first strip from said feeder means through said applicator station to said first assembly station and second and third conveyors for carrying said second and third strips, respectively, directly to said first assembly station.
 35. The automatic assembly machine of claim 34, further including a second applicator station for applying adhesive to two edges of said sheet, a second assembly station, means for conveying said sheet to said second assembly station and into longitudinal alignment with fourth and fifth strips; means for vertically aligning corresponding edges of said fourth and fifth strips with said adhesive-coated edges of said sheet; a second roller station; means for advancing said sheet and said fourth and fifth strips into said second roller station to press said last-named corresponding edges together to form bonded joints, whereby a composite sheet is formed, said composite sheet being delivered to said delivery station.
 36. The automatic assembly machine of claim 35, wherein said feeder means is adapted to supply fourth and fifth strips with each set of strips, and fourth and fifth conveyor means for carrying said fourth and fifth strips, respectively, from said feeder means directly to said second assembly station.
 37. The automatic assembly machine of claim 36, further including control circuit means for synchronizing the operation of said machine, whereby said sets of five strips are fed periodically to said machine for assembly into composite sheets, said control circuit means including means for detecting a malfunction in said machine and for shutting down said machine in response thereto.
 38. The automatic assembly machine of claim 37, wherein said control circuit means includes first and second sensing means for said first and second assembly stations for detecting the longitudinal and vertical alignment of said strips, and timer means responsive to a malfunction of said machine to disable said feeder means and thereafter to shut down said assembly and roller stations.
 39. The automatic assembly machine of claim 21, further including control circuit means for synchronizing the operation of said machine and wherein said composite sheet formed thereby is an insole sheet for use in making insoles for shoes and said adhesive comprises a fast-setting thermoplastic adhesive, whereby said assembly machine can produce said composite insole sheets at a relatively high rate of speed.
 40. The automatic assembly machine of claim 21, wherein said first strip is a toe strip for an insole; said roller station further including means for producing indentations in said toe strip during assembly of said composite sheet.
 41. The machine of claim 40, wherein said means for producing indentations includes a toothed roller and a smooth roller forming a nip through which said toe strip passes. 